Shredder/compactor auger system
BACKGROUND OF THE INVENTION 
     The present invention is generally directed to systems for pyrolysis of hazardous materials. More specifically, the invention is directed to systems for feeding hazardous materials to a combustion chamber or kiln. 
     The incineration of hazardous waste materials within the United States is closely controlled and monitored by the United States Environmental Protectional Agency. In connection therewith, the U.S. Environmental Protection Agency has issued strict guidelines for the construction of hazardous material incinerators and systems for feeding such material to the incinerators. As a result, a variety of systems have been developed for feeding such material to the incinerators. 
     U.S. Pat. No. 3,658,654, the teachings of which are incorporated herein by reference, discloses an apparatus for the pyrolysis of solids containing carbonatious materials including a cylindrical substantially horizontal pyrolysis vessel together with solids input and removal means communicating with the vessel. Solids are conveyed through the pyrolysis vessel by means of an auger-type conveyor. Heating means are provided for heating solids between the input and removal means. Gas input and withdrawal means permit the input and removal of gas from the pyrolysis vessel, and gas delivery means are provided for delivering gas to subsequent processing equipment. 
     U.S. Pat. No. 3,921,545 discloses a furnace with a conveyor installation with a screw conveyor. The screw conveyor is used for transporting solid combustible materials such as wood waste into the furnace. 
     U.S. Pat. No. 4,087,334 discloses a seal arrangement for a rotary drum assembly. A first cylindrical drum member having an inlet portion for receiving materials to be treated, such as preheated coal and char includes a longitudinal axis in an outward portion through which the treated materials are discharged into the inlet portion of a second cylindrical drum member. The second drum member is independently supported for rotation relative to the first drum member and has a longitudinal axis co-planarly aligned with the longitudinal axis of the first drum member such that the drum members are concentrically positioned in tandem. A sealing assembly is connected to the first and second drum members for longitudinal movement with the drum members during expansion and contraction of the drum members as they are subjected to different temperatures. The sealing assembly includes a running seal member that is secured to the periphery of the respective drum members and a static seal ring assembly that is movably positioned on the outer cylindrical surface of an annular support member that supports the respective drum members. A plurality of piston cylinder assemblies surround the annular support member, and each includes a piston rod arranged in abutting relation to the static seal ring assembly to maintain the seal ring assembly in sealing relation with the running seal upon longitudinal movement of the first drum member. 
     U.S. Pat. No. 4,616,573 discloses a metering feeder for delivery solid fuels, such as municipal or industrial refuse, for combustion. The metering feeder includes a pair of generally vertically arranged hoppers. An upper hopper containing relatively compacted or intertangled fuel discharges metered amounts of fuel into a lower hopper through the action of a ram-type pusher. Fuel discharged from the upper hopper is dropped into the lower hopper to develop sufficient kinetic energy to decompact the fuel. An upwardly inclined conveyor includes fuel from the lower hopper at an independently metered rate under optional control of a combustion control system. The action of the inclined conveyor further decompacts the fuel by underraking and mixing, thereby providing a well controlled, uniform, loose density fuel for combustion. The conveyor has a closed course of cleats with cyclically moves to remove fuel. The cleats extend in acute angular relation to the direction of movement for improved performance. 
     U.S. Pat. No. 4,714,031 discloses a combustor feeding arrangement for feeding material to the open end of a combustor including a vertical chute leading to doorway to the combustor which is normally closed by a biased door. The system further includes a stepped ram reciprocating at the bottom of the chute for feeding material through the door and into the combustor. The chute is opened to atmosphere and lacks an urging device to convey feed material toward the next function. 
     In all of the above-identified systems, there is the possibility that the material to be incinerated can prematurely combust and cause fires, explosions, and the like. This can damage the equipment and can be a safety hazard to supervisory personnel. 
     SUMMARY OF THE INVENTION 
     The present invention provides an improved system for decompacting or shredding and feeding compacted or packaged hazardous materials into a combustion chamber. Further, the invention provides that the decompaction occurs in an environment that reduces the risk of premature combustion. 
     To these ends, the invention provides a hazardous waste shredder/feeder system for a kiln or incinerator wherein the waste is first conveyed to an airlock chamber and introduced therein, then conveyed from the airlock chamber to a shredding chamber, and then conveyed from the shredding chamber to a feeding chamber from whence it is fed into the kiln or incinerator. The airlock chamber serves to isolate the shredding and feeding chambers from outside air. 
     The following words are used interchangeably throughout the specification and claims: kiln, combustion chamber, incinerator, and pyrolysis chamber. No limitation in meaning is intended by the use of one word instead of another unless otherwise noted. 
     Further, the following words and their conjunctions are also used interchangeably throughout the specification and claims: burn, combust, incinerate, and pyrolysis. No limitation in meaning is intended by the use of one word instead of another unless otherwise noted. 
     Yet further, when used herein, the word conveyor is to be read broadly an encompassing any means for conveying unless otherwise qualified. 
     The invention provides in an exemplary embodiment, a shredder/feeder system that automatically and sequentially moves combustible material, preferably palletized hazardous wastes contained either in drums, pails, crates or boxes, from a ground level material mover (normally being a fork lift), and into an elevator conveyor via a first conveyor, preferably a roller conveyor. The elevator then lifts the hazardous waste material to an upper level discharge point, at which point the material is transferred to a second conveyor or conveyors, preferably a roller conveyor. The hazardous waste material advances on the second conveyor/conveyors until it is in line with a hermetically sealed air lock chamber. At that point, an automated mechanism moves the material onto a third conveyor (preferably a roller conveyor) that may be oriented 90° to 180° from the second conveyor/conveyors. 
     The third conveyor moves the material through an automated guillotine entry door into the airlock chamber. Once the material has entered the airlock chamber, a suitable control system closes the guillotine entry door and initiates a purge of oxygen in the airlock chamber, wherein a gas, preferably nitrogen, replaces evacuated oxygen or air. An internal oxygen sensor initiates shut down of the purge when a predetermined oxygen concentration is reached. The purged oxygen air exits the airlock chamber via a conduit leading to a combustion air blower. When the purge is shut down, a control system opens a guillotine exit door to permit further travel of the hazardous material from the airlock chamber into a shredder chamber. 
     The third conveyor at that time moves the material from the airlock chamber to the shredder chamber by conveying the material until it falls off one end of the conveyor. When the pallet of hazardous material has fallen into the shredder chamber, the control system closes the second guillotine door to isolate the shredder from atmosphere. Then suitable shredder or shredders operates to shred the waste material for a predetermined time cycle in an upper portion of the chamber. The shredded waste charge is allowed to fall into a lower feeder auger which then extrudes the material into the combustion chamber. 
     The shredder/feeder chamber contains several oxygen analyzers which continuously monitor oxygen concentration. In the event oxygen concentration exceeds a predetermined level, the control system automatically stops all equipment operation and closes an isolation door to keep waste charge material from entering the combustion chamber. 
     During such an event, a purge is activated, wherein nitrogen gas is introduced and continues until the oxygen concentration is reduced to a predetermined level. When this occurs, the control system opens the isolation door and the system is reactivated to deliver the shredded waste material to the combustion chamber. 
     Thus safer processing of combustible hazardous materials is accomplished by the isolation of hazardous materials from atmosphere during processing and by safely processing flammable and low flashpoint solid, semi-solid and sludge type waste without repackaging thereby eliminating employee exposure and costs of repackaging. 
     The invention accomplishes safely shredding low flash point wastes and provides a continuous stable feed to a kiln therein providing more stable kiln operating conditions. 
     By providing a shredded flammable waste feed to a kiln, burnout and kiln capacity is improved in both oxidizing and pyrolysis modes of kiln operation. 
     The method of feeding solid and semi-solid combustible wastes continuously to a kiln is totally automated and an explosion proof atmosphere is maintained in the airlock and main feed chamber. 
     These and other features and aspects of the invention will become more apparent with reference to the following detailed description of the presently preferred embodiments and accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a schematic of an arrangement embodying principles of the invention. 
     FIG. 2 is a schematic of another arrangement embodying principles of the invention. 
     FIG. 3 is a cut-away isometric view of an auger chamber of the arrangement of FIG. 2. 
     FIG. 4 is a cut-away isometric view of shear shredders and chamber of the arrangement of FIG. 2. 
     FIG. 5 is a cut-away plan view illustration of a feed chamber for grinding and augering material and feeding same to a Auger/Feeder chamber. 
     FIG. 6 is an elevational view of an auger feeder used to feed combustible material into a combustion chamber. 
     FIG. 7 is a plan view of an alternate feeding arrangement for the systems of FIGS. 1 and 2 wherein a shredder/auger machine is oriented 90° to a center line of a combustion chamber with an additional feed auger/shredder positioned on the center line of the combustion chamber. 
    
    
     DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS 
     In FIGS. 1 and 2 there are illustrated two arrangements embodying principles of the invention. In the illustrated arrangements, material, preferably, palletized hazardous waste charge, is conveyed to a combustion chamber via an isolated shredding operation. Accordingly, because the shredding operation is isolated from the remainder of the arrangement, the material can be safely transported into the combustion chamber with a reduced risk of explosions and the like. 
     As illustrated in FIGS. 1, 5, and 6 in one presently preferred embodiment, combustible material 3, preferably palletized hazardous material, which can be contained in steel drums (as illustrated) is conveyed along a path to a kiln 32, as indicated by arrows 9. In the process, the material 3 is isolated from oxygen and shredded or decompacted. 
     To this end, a ground level conveyor 2, preferably a roller conveyor, is used to transfer the material 3 onto a vertical conveyor 4. The material 3 is elevated above ground level by the vertical conveyor 4 and transferred onto a conveyor 100, preferably a roller conveyor, at a top terminal of the vertical conveyor 4. The conveyor 100 then transfers the material 3 to another conveyor 5, preferably a roller conveyor, through a doorway 102 in the vertical conveyor 4 housing. Of course, the conveyor 100 can be a part of the vertical conveyor 4. 
     The material 3 is then transferred along a series of conveyors, commencing with the roller conveyor 5 and including conveyors 6, 8, 108, and 104 along the direction defined by an arrow 9. It is to be understood, however, that the number of conveyors used can vary depending on the particular needs of a given arrangement. The important thing is to provide transport of the material 3. This can be accomplished using one or more conveyors. 
     With continuing reference to FIG. 1, it can be seen that the material 3 is transferred from the conveyor 5 to the conveyor 6. Once the material 3 reaches the end of the conveyor 6, it is sensed by a first control system 47 which stops the conveying of the material 3. In a preferred embodiment, the conveyor 6 comprises a 90° transfer station. Once the material 3 is stopped on the conveyor 6, it is transferred onto yet another conveyor 8 at which point transport of the material 3 continues. 
     When the material 3 reaches the end of conveyor 8, it is sensed by control system 48 which is operatively connected to entry door 10 of an airlock chamber 14. Door 10 preferably is of the guillotine type which opens and closes a doorway by raising and lowering of the door 10. 
     With the door 10 in its open position, the material 3 is transferred to a feed conveyor 108 located within the airlock chamber 14. A sensor 11, preferably a limit switch positioned adjacent the conveyor 108 is used to sense the presence of the material 3 within the airlock chamber 14. When the sensor 11 senses the material 3 within the airlock chamber 14, the conveyor 108 is temporarily halted so that a purge of oxygen can take place and the door 10 is closed. 
     To effect a purge of oxygen once the door 10 is closed, a third control system 49 activates a purge whereby oxygen is replaced by a suitable gas, e.g., nitrogen gas, which gas is introduced into the airlock chamber 14 via purge lines 13 and air is evacuated from the airlock chamber 14 and an adjacent main feeder chamber 22 via a conduit 20. The conduit 20 is connected to a combustion air blower (not illustrated) associated with the kiln 32. Thus, the air evacuated from the airlock chamber 14 and main feeder chamber 22 is provided to the kiln 32. 
     At the same time, the suitable gas, e.g., nitrogen, is introduced into the airlock chamber 14 and main feeder chamber 22 via purge lines 13. Oxygen sensors 12 continuously monitor the concentrations of oxygen in the atmospheres within the airlock chamber 14, and main feeder chamber 22. When the concentration of oxygen is sufficiently low, the oxygen purge is terminated by the control system 49. 
     The elimination of oxygen within the sealed airlock chamber 14 and main feeder chamber 22 serves to prevent the occurrence of premature combustion of the material 3 via explosions, fires, or the like. Should this occur, however, a fire suppression system 17, preferably a sprinkler or foaming system is provided. Further, explosion doors 16 are provided. 
     When the oxygen purge is terminated, the control system 49 opens airlock chamber exit door 18. Exit door 18 preferably is also of the guillotine type which can be raised and lowered to open and close, respectively, an exit doorway. The feed conveyor 108 is then activated and the material 3 is transported to conveyor 104 which is positioned within the main feeder chamber 22. The guillotine entry door 10 remains closed, and thus, the airlock chamber 14 and main feeder chamber 22 remain isolated from atmosphere. 
     As illustrated, the conveyor 104 transports the material 3 until it falls off the end of the conveyor 104. Since the end of the conveyor 104 preferably extends to about a center of the main feeder chamber 22, the material 3 preferably falls along a central vertical line of the main feeder chamber 22. As it falls, the material 3 activates a sensor 23, preferably tripping a limit switch, which in turn is coupled to the control system 50. The control system 50 reacts by closing the exit door 18 to isolate the main feeder chamber 22 from the airlock chamber 14 so that another charge of material can be introduced into the airlock chamber 14. 
     The material 3 falls from the conveyor 104 into a shredder 34 which shreds the material 3 as well as the drum in which it is contained, if any, and the pallet on which the drum is carried, if any. It should be appreciated that the shredder 34 preferably has sufficient power and strength to shred wooden pallets as well as steel drums. 
     The shredder 34 preferably comprises two parallel flighted opposing cone augers having radial knives or teeth disposed thereabout. The material 3 (and drums and pallets in which it is contained and on which it is mounted) is continuously sliced and ripped by the knives for a predetermined cycle. To this end, the material 3 (and drums and pallets) is held in contact with the shredder 34 by means of doors 21. 
     Following termination of the shredding cycle, the doors 21 open and allow shredded matter 45 to fall into an auger 27 contained within a chamber 30. The auger 27, by auger action, will further shred the shredded material 45. At the same time, the auger 27 will extrude the shredded matter 45 through a constrictive throat 37, with surrounding water cooled injection tube 39, and into kiln 32. The auger 27 is illustrated in greater detail in FIGS. 5 and 6. 
     As illustrated, the auger 27 preferably is tapered such that the matter 45 is forced into a continuously decreasing diameter conduit so as to compact the matter as it is extruded into the kiln 32. Further, the auger 27 preferably comprises two parallel augers 27A and 27B so that the matter 45 is further shredded and mixed. 
     To increase safety in operation of the illustrated apparatus, a plurality of oxygen sensors 38 are positioned between the discharge of the shredder 34 and the inlet of auger 27. These oxygen sensors 38 are operatively coupled and serve to signal the control system 50 whenever the oxygen concentration in that area exceeds a predetermined safety level. 
     Whenever the oxygen sensed by the sensors 38 exceeds the predetermined safety level, the control system 50 preferably halts operation of all operating equipment and initiates an oxygen purge. To this end, the control system 50 closes a kiln isolation door 25 and a suitable gas such as nitrogen is introduced into the chamber 22 via suitable ports 26. 
     Once the oxygen concentration is reduced to a level below the safety level, the purge is terminated, the kiln isolation door 25 is opened and the remaining operating equipment is restarted. 
     To effect control over the entire arrangement, a control system 43 is provided. The system 43 preferably includes an interface panel by which supervisory personnel can monitor and control the various devices used to convey, shred, and feed material to be consumed in the kiln 32. The system 43, therefore, preferably communicates with and interacts with the other control systems 47, 48, 49, and 50. 
     In FIGS. 2-4, there is illustrated another arrangement embodying principles of the invention. It can be appreciated that many aspects of the arrangement of FIG. 2 are similar to that of FIG. 1 and accordingly, similar components are referenced by identical reference numerals. 
     As illustrated, the process for conveying the material 3 from ground to the main feeder chamber 22 in the arrangement of FIG. 2 is similar, if not identical, to that described in connection with FIG. 1. Accordingly, a description of that portion will not be repeated. It should be noted, however, that conveyors 108 and 104 of FIG. 1 are combined as a single continuous conveyor 108 in FIG. 2. Otherwise the process is identical. 
     In the arrangement of FIG. 2, the material 3 that falls off the end of the conveyor 108 falls onto a swing gate 28 rather than directly into a shredder 7 (which is similar to the shredder 34). The swing gate 28 is operatively moved by a ram 25 between upper and lower positions. In its upper position, the gate 28, preferably a substantially planar swinging door, is substantially horizontally positioned. In contrast, in its lower position, the gate 28 is substantially vertically positioned so that material thereon slides off. It should be understood that the material 3 is dropped onto the swing gate 28 when it is in its upper position, and then the gate 28 is lower to allow the material 3 to slide off and to drop between the rollers of the shredder 7. 
     Thus, the swing gate 28 can serve to control the feeding of material 3 to the shredder 7 and to lessen the impact force of the material 3 as it falls into the shredder 7 as the material 3 falls from a lower height. 
     Also included in the arrangement of FIG. 2 is a reciprocating hydraulic ram 19 that includes a pusher arm 19A. The ram 19, by operatively moving the arm 19A toward and away from the shredder 7 can serve to ensure that the material 3 is positively feed between the rollers of the shredder 7. The gate 28 and ram 19 are automatically controlled by control system 50. 
     The shredded matter 45 that exits from the shredder 7, falls into chamber 35 and into a second shredder 107 that, preferably, is identical to the shredder 7. At that point, the matter 45 is reshredded by the shredder 107. The matter 45 is then discharged from the shredder 107 and into an auger 44 that serves to feed the shredded mater 45 into the kiln 32. As illustrated, an agitator 40 and plural nitrogen cannons 31 are installed in a lower vertical drop chute 30 that extends between the shredder 107 and the auger 44. The agitator 40 and nitrogen cannons 31 serve to promote the flow of shredded matter 45 to the auger 44. 
     As with the arrangement of FIG. 1, the arrangement of FIG. 2 includes multiple oxygen sensors 38 in the chamber 35, which serve to provide signals to a control system 43 if the oxygen concentration within the chamber 35 rises above a predetermined safety level. If the oxygen level in the chamber 35 is above the predetermined safety level, the control system 43 can stop all equipment and close the kiln isolation door 25 and commence an oxygen purge. Again, once the oxygen concentration is reduced below the safety level, the purge is terminated and the kiln door 25 is reopened. 
     In FIG. 3 the preferred auger 44 is illustrated in isometric view. Additionally, the relative positioning of a nitrogen cannon 31 can be seen. 
     In FIG. 4, an isometric view of the shredder 7 is illustrated. It can be seen that the shredder basically comprises two parallel rollers 7A and 7B. Each of rollers 7A and 7B preferably comprises a series of circular disk members with protruding teeth. The series of disk-like members are separated by short cylindrical members so that the disk-like members are spaced apart along an axis of rotation. Further, the teeth of the disk-like members are positioned out of axial alignment so that they do not rotate through a common axial line at the same time. Instead, the teeth will dig into the matter to be shredded at different times. 
     However, it should be understood that the shredder 7 merely represents a preferred embodiment. It is possible to replace the shredder 7 with another suitable type shredder that effectively shreds and tears apart the material 3 and any accompanying pallet and drum. 
     Further, it can be appreciated that the shredder illustrated in FIG. 4 can also be employed as the shredder 34. 
     FIG. 7 illustrates in plan view an alternate arrangement for feeding shredded matter 45 into the kiln 32. As illustrated, a first single tapered auger 41 is provided for the actual extrusion of matter 45 into the kiln 32. Positioned at right angles to the auger 41 is a second, larger, tapered auger 27. It can be appreciated that the shredded matter 45 will be able to fall more easily into the space provided by the larger auger 44. Then, the auger 27 will compress the matter 45 so that it is more easily received by the smaller auger 41. 
     While a preferred embodiment has been shown, modifications and changes may become apparent to those skilled in the art which shall fall within the spirit and scope of the invention. It is intended that such modifications and changes be covered by the attached claims.